U.S. patent application number 12/916462 was filed with the patent office on 2011-11-03 for methods for processing substrates in process systems having shared resources.
This patent application is currently assigned to APPLIED MATERIALS, INC.. Invention is credited to Dermot Cantwell, Kenneth S. Collins, James P. Cruse, Charles Hardy, Evans Lee, Andrew Nguyen, Benjamin Schwarz, Zhifeng Sui, Ming Xu.
Application Number | 20110266256 12/916462 |
Document ID | / |
Family ID | 44857289 |
Filed Date | 2011-11-03 |
United States Patent
Application |
20110266256 |
Kind Code |
A1 |
Cruse; James P. ; et
al. |
November 3, 2011 |
METHODS FOR PROCESSING SUBSTRATES IN PROCESS SYSTEMS HAVING SHARED
RESOURCES
Abstract
Methods for processing substrates in twin chamber processing
systems having first and second process chambers and shared
processing resources are provided herein. In some embodiments, a
method may include providing a substrate to the first process
chamber of the twin chamber processing system, wherein the first
process chamber has a first processing volume that is independent
from a second processing volume of the second process chamber;
providing one or more processing resources from the shared
processing resources to only the first processing volume of the
first process chamber; and performing a process on the substrate in
the first process chamber.
Inventors: |
Cruse; James P.; (Santa
Cruz, CA) ; Cantwell; Dermot; (Sunnyvale, CA)
; Xu; Ming; (San Jose, CA) ; Hardy; Charles;
(San Jose, CA) ; Schwarz; Benjamin; (San Jose,
CA) ; Collins; Kenneth S.; (San Jose, CA) ;
Nguyen; Andrew; (San Jose, CA) ; Sui; Zhifeng;
(Fremont, CA) ; Lee; Evans; (Milpitas,
CA) |
Assignee: |
APPLIED MATERIALS, INC.
Santa Clara
CA
|
Family ID: |
44857289 |
Appl. No.: |
12/916462 |
Filed: |
October 29, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61330021 |
Apr 30, 2010 |
|
|
|
Current U.S.
Class: |
216/59 ; 216/58;
427/248.1 |
Current CPC
Class: |
H01J 37/32899 20130101;
H01L 21/6719 20130101 |
Class at
Publication: |
216/59 ;
427/248.1; 216/58 |
International
Class: |
C23F 1/00 20060101
C23F001/00; C23C 16/455 20060101 C23C016/455 |
Claims
1. A method of processing substrates in a twin chamber processing
system having a first process chamber, a second process chamber,
and shared processing resources, comprising: providing a substrate
to the first process chamber of the twin chamber processing system,
wherein the first process chamber has a first processing volume
that is independent from a second processing volume of the second
process chamber; providing one or more processing resources from
the shared processing resources to only the first processing volume
of the first process chamber; and performing a process on the
substrate in the first process chamber.
2. The method of claim 1, wherein the shared processing resources
comprise at least one of a shared gas panel or a shared vacuum
pump.
3. The method of claim 1, wherein providing one or more processing
resources comprises providing a process gas from a shared gas
panel, wherein the process gas bypasses the second process
chamber.
4. The method of claim 3, wherein the process gas bypassing the
second process chamber is diverted to a foreline of the first
process chamber.
5. The method of claim 1, further comprising: performing a service
operation on the one of the first process chamber or the second
process chamber the substrate has not been provided to.
6. The method of claim 5, wherein performing a service operation
comprises: performing at least one of a maintenance, cleaning,
testing or monitoring process.
7. The method of claim 5, further comprising: simultaneously
performing the process on the substrate in the first process
chamber and the service operation on the second process
chamber.
8. The method of claim 1, further comprising: pausing the process
being performed on the substrate to enable the second process
chamber to use at least one of the one or more shared
resources.
9. A method of processing substrates in a twin chamber processing
system having a first process chamber, a second process chamber,
and shared processing resources, wherein the shared processing
resources comprise at least one of a shared gas panel or a shared
vacuum pump, the method comprising: providing a substrate to the
first process chamber of the twin chamber processing system,
wherein the first process chamber has a first processing volume
that is independent from a second processing volume of the second
process chamber; providing a process gas from a shared gas panel to
only the first processing volume of the first process chamber,
wherein the process gas bypasses the second process chamber and is
diverted to a foreline of the first process chamber; and performing
a process on the substrate in the first process chamber.
10. A computer readable medium, having instructions stored thereon
which, when executed, causes a twin chamber processing system
having a first process chamber, a second process chamber, and
shared processing resources to perform a method, comprising:
providing a substrate to the first process chamber of the twin
chamber processing system, wherein the first process chamber has a
first processing volume that is independent from a second
processing volume of the second process chamber; providing one or
more processing resources from the shared processing resources to
only the first processing volume of the first process chamber; and
performing a process on the substrate in the first process
chamber.
11. The computer readable medium of claim 10, wherein providing one
or more processing resources comprises providing a process gas from
a shared gas panel, wherein the process gas bypasses the second
process chamber.
12. The computer readable medium of claim 11, wherein the process
gas bypassing the second process chamber is diverted to a foreline
of the first process chamber.
13. The computer readable medium of claim 10, further comprising:
performing a service operation on the second process chamber.
14. The computer readable medium of claim 13, wherein performing a
service operation comprises: performing at least one of a
maintenance, cleaning, testing, or monitoring process.
15. The computer readable medium of claim 10, further comprising:
simultaneously performing the process on the substrate in the first
process chamber and the service operation on the second process
chamber.
16. The computer readable medium of claim 10, further comprising:
pausing the processing being performed on the substrate to enable
the second process chamber to use at least one of the one or more
shared resources.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. provisional patent
application Ser. No. 61/330,021, filed Apr. 30, 2010, which is
herein incorporated by reference.
FIELD
[0002] Embodiments of the present invention generally relate to
substrate processing systems.
BACKGROUND
[0003] In order to increase productivity and reduce cost of
ownership, substrate processing systems have been developed that
process multiple substrate simultaneously. This has been done
conventionally by using process chambers that can process multiple
substrates in a common volume. However, the inventors have
discovered that uniformity issues may arise when using multiple
substrates in a common volume that do not arise in single substrate
processing systems. In addition, the inventors have observed that
conventional single substrate processing systems are unable to
satisfactorily share chamber resources, thereby frustrating
attempts to reduce the cost of ownership and increase process
throughput.
[0004] Accordingly, the inventors have provided methods for
processing substrates in twin chamber processing systems using
shared chamber resources.
SUMMARY
[0005] Methods for processing substrates in twin chamber processing
systems having first and second process chambers and shared
processing resources are provided herein. In some embodiments, a
method may include providing a substrate to the first process
chamber of the twin chamber processing system, wherein the first
process chamber has a first processing volume that is independent
from a second processing volume of the second process chamber;
providing one or more processing resources from the shared
processing resources to only the first processing volume of the
first process chamber; and performing a process on the substrate in
the first process chamber.
[0006] In some embodiments, a computer readable medium may be
provided, having instructions stored thereon which, when executed,
causes a twin chamber processing system having a first process
chamber, a second process chamber, and shared processing resources
to perform any of the methods disclosed herein.
[0007] Other and further embodiments of the present invention are
described below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Embodiments of the present invention, briefly summarized
above and discussed in greater detail below, can be understood by
reference to the illustrative embodiments of the invention depicted
in the appended drawings. It is to be noted, however, that the
appended drawings illustrate only typical embodiments of this
invention and are therefore not to be considered limiting of its
scope, for the invention may admit to other equally effective
embodiments.
[0009] FIG. 1 depicts a schematic top view of a processing system
in accordance with some embodiments of the present invention.
[0010] FIG. 2 depicts a schematic side view of a twin chamber
processing system in accordance with some embodiments of the
present invention.
[0011] FIGS. 3 and 4 depict flow charts for methods of processing
substrates in a twin chamber processing system in accordance with
some embodiments of the present invention.
[0012] To facilitate understanding, identical reference numerals
have been used, where possible, to designate identical elements
that are common to the figures. The figures are not drawn to scale
and may be simplified for clarity. It is contemplated that elements
and features of one embodiment may be beneficially incorporated in
other embodiments without further recitation.
DETAILED DESCRIPTION
[0013] Methods for processing substrates in a twin chamber
processing system are disclosed herein. The inventive methods
advantageous control operation of chamber processes, such process
gas flow, plasma generation, and the like, when shared resources
are used between each chamber of a twin chamber processing system,
or other processing systems having two or more process chambers
having shared resources, such that processes can be run
simultaneously on substrates in each process chamber and process
quality can be maintained.
[0014] An exemplary twin chamber processing system as disclosed
herein may be a standalone processing system or a part of a cluster
tool having several twin chamber processing systems coupled
thereto, for example, such as a processing system 100 illustrated
in FIG. 1. Referring to FIG. 1, in some embodiments, the processing
system 100 may generally comprise a vacuum-tight processing
platform 104, a factory interface 102, one or more twin chamber
processing systems 101, 103, 105 and a system controller 144.
Examples of a processing system that may be suitably modified in
accordance with the teachings provided herein include the
CENTURA.RTM. integrated processing system, one of the PRODUCER.RTM.
line of processing systems (such as the PRODUCER.RTM. GT.TM.),
ADVANTEDGE.TM. processing systems, or other suitable processing
systems commercially available from Applied Materials, Inc.,
located in Santa Clara, Calif. Other processing systems may be
adapted to benefit from the invention. Although disclosed herein
with reference to a twin chamber processing system, other multiple
chamber processing systems (e.g., two or more) having shared
resources may be modified and operated in accordance with the
teachings provided herein. Another example of a twin chamber
processing system is described in U.S. Provisional Patent
Application Ser. No. 61/330,156, filed Apr. 30, 2010, by Ming Xu et
al., and entitled, "Twin Chamber Processing System."
[0015] The platform 104 includes a vacuum substrate transfer
chamber 136 having the one or more twin chamber processing systems
101, 103, 105 (three shown in FIG. 1) coupled thereto. Each twin
chamber processing system includes two process chambers (e.g., 110
and 111, 112 and 132, and 120 and 128). The platform further
includes at least one load-lock chamber 122 (two shown in FIG. 1)
that are coupled to the vacuum substrate transfer chamber 136. The
factory interface 102 is coupled to the transfer chamber 136 via
the load lock chambers 122.
[0016] Each twin chamber processing system 101, 103, 105 includes
independent processing volumes that may be isolated from each
other. Each twin chamber processing system 101, 103, 105 may be
configured to share resources (e.g., process gas supply, vacuum
pump, or the like) between each process chamber of the twin chamber
processing system as discussed below and illustrated in FIG. 2.
[0017] The factory interface 102 may comprise at least one docking
station 108 and at least one factory interface robot (two shown in
FIG. 1) 114 to facilitate transfer of substrates. The docking
station 108 may be configured to accept one or more (two shown in
FIG. 1) front opening unified pods (FOUPs) 106A-B. The factory
interface robot 114 may comprise a blade 116 disposed on one end of
the robot 114 configured to transfer the substrate from the factory
interface 102 to the processing platform 104 for processing through
the load lock chambers 122. Optionally, one or more metrology
stations 118 may be connected to a terminal 126 of the factory
interface 102 to facilitate measurement of the substrate from the
FOUPs 106A-B.
[0018] Each of the load lock chambers 122 may comprise a first port
123 coupled to the factory interface 102 and a second port 125
coupled to the transfer chamber 136. The load lock chambers 122 may
be coupled to a pressure control system (not shown) which pumps
down and vents the load lock chambers 122 to facilitate passing the
substrate between the vacuum environment of the transfer chamber
136 and the substantially ambient (e.g., atmospheric) environment
of the factory interface 102.
[0019] The transfer chamber 136 has a vacuum robot 130 disposed
therein. The vacuum robot 130 may include one or more transfer
blades 134 (two shown in FIG. 1) coupled to a movable arm 131. For
example, in some embodiments, where twin chamber processing systems
are coupled to the transfer chamber 136 as shown, the vacuum robot
130 may comprise two parallel blades 134 configured such that the
vacuum robot 130 may simultaneously transfer two substrates 124,
126 from the load lock chambers 122 to the process chambers of a
twin chamber processing system, for example, process chambers 110,
111 of the twin chamber processing system 101. Alternatively, in
some embodiments, the vacuum robot 130 may be configured to
selectively provide a substrate 124 to one process chamber of the
twin chamber processing system, for example, process chamber 110 of
the twin chamber processing system 101. In such embodiments, in
operation, the vacuum robot 130 may provide a substrate to only one
of the process chambers, or may sequentially provide a first
substrate to a first process chamber of the twin processing chamber
system (e.g., provide substrate 126 to process chamber 111)
followed by a second substrate to a second process chamber of the
twin processing chamber system (e.g., provide substrate 124 to
process chamber 110).
[0020] The process chambers 110, 111 or 112, 132 or 128, 120 of
each twin chamber processing system 101, 103, 105 may be any type
of process chamber utilized in substrate processing, for example,
such as etch chambers, deposition chambers, or the like. In some
embodiments, each process chamber of the twin chamber processing
system is configured for the same function, for example, etching.
For example, in embodiments where each process chamber of a twin
chamber processing system is an etch chamber, each process chamber
may include a plasma source, for example, an inductive or
capacitively coupled plasma source, a remote plasma source or the
like. Further, each process chamber of a twin chamber processing
system may use a halogen-containing gas, for example, provided by a
shared gas panel (as discussed below), to etch substrates (e.g.,
substrates 124, 126) disposed therein. Examples of
halogen-containing gas include hydrogen bromide (HBr), chlorine
(Cl.sub.2), carbon tetrafluoride (CF.sub.4), and the like. For
example, after etching the substrates 124, 126, halogen-containing
residues may remain on the substrate surface. The
halogen-containing residues may be removed by a thermal treatment
process in the load lock chambers 122, or by other suitable
means.
[0021] FIG. 2 depicts a schematic side view of a twin chamber
processing system, for example twin chamber processing system 101,
in accordance with some embodiments of the present invention. The
twin chamber processing system 101 includes the process chambers
110, 111, wherein the process chambers 110, 111 share resources,
for example, such as a shared vacuum pump 202 and a shared gas
panel 204 as shown in FIG. 2. In some embodiments, each twin
chamber processing system coupled to the processing system 100 may
be similarly configured.
[0022] The process chamber 110 (e.g., a first process chamber) has
a first processing volume 208 that includes a first substrate
support 201 disposed therein to support a substrate (first
substrate 203 shown in FIG. 2). The process chamber 110 further
includes a first vacuum pump 206 for maintaining a first operating
pressure in the first processing volume 208. The first vacuum pump
206 may be, for example, a turbomolecular pump or the like. The
first vacuum pump 206 may include a low pressure side 205 proximate
the first processing volume 208 and a high pressure side 207 which
may be selectively coupled to the shared vacuum pump 202 as
discussed below. The first vacuum pump 206 may be selectively
isolated from the first processing volume 208 by a first gate valve
210 disposed between the first processing volume 208 and the first
vacuum pump 206, for example proximate the low pressure side 205 of
the first vacuum pump 206.
[0023] The process chamber 111 (e.g., a second process chamber) of
the twin chamber processing system 101 includes a second processing
volume 214 having a second substrate support 209 disposed therein
to support a substrate (second substrate 215 shown in FIG. 2). The
process chamber 111 further includes a second vacuum pump 212 for
maintaining a second operating pressure in the second processing
volume 214. The second vacuum pump 212 may be, for example, a
turbomolecular pump or the like. The second vacuum pump 212 may
include a low pressure side 211 proximate the second processing
volume 214 and a high pressure side 213 which may be selectively
coupled to the shared vacuum pump 202 as discussed below. The
second vacuum pump 212 may be selectively isolated from the second
processing volume 214 by a second gate valve 216 disposed between
the second processing volume 214 and the second vacuum pump 212,
for example proximate the low pressure side 211 of the second
vacuum pump 212.
[0024] The first and second processing volumes 208, 214 may be
isolated from each other to facilitate substantially independent
processing of substrates in each respective process chamber 110,
111. The isolated processing volumes of the process chambers within
the twin chamber processing system advantageously reduces or
eliminates processing problems that may arise due to
multi-substrate processing systems where the processing volumes are
fluidly coupled during processing. For example, in some
embodiments, a substrate may be processed in one of the process
chambers of the twin chamber processing system while the other
process chamber remains idle. In such embodiments, the shared
resources may be diverted from the idle process chamber and
provided only to the process chamber having the substrate being
processed therein. In some embodiments, the idle process chamber
may be decoupled from the shared resources and/or disabled to allow
for service operations (e.g. maintenance, cleaning, testing,
monitoring, or the like) to be performed without affecting the
process being performed in the other process chamber. Non-limiting
examples of such service operations and methods of performing such
services may be found in U.S. Provisional Patent Application Ser.
No. 61/330,177, filed Apr. 30, 2010, by James P. Cruse et al., and
entitled, "Methods for Monitoring Processing Equipment."
[0025] However, the twin chamber processing system further
advantageously utilizes shared resources that facilitate reduced
system footprint, hardware expense, utilities usage and cost,
maintenance, and the like, while at the same time promoting higher
substrate throughput. For example, shared hardware may include one
or more of a process foreline and roughing pump, AC distribution
and DC power supplies, cooling water distribution, chillers,
multi-channel thermo controllers, gas panels, controllers, and the
like.
[0026] The shared vacuum pump 202 may be selectively coupled to or
isolated from any of the first and second processing volumes 208,
214 or the first and second vacuum pumps 206, 212. For example, the
shared vacuum pump 202 may be coupled to the first and second
processing volumes 208, 214 for reducing a pressure in each
processing volume below a critical pressure level prior to opening
the first and second gate valves 210, 216. For example, the
critical pressure level may be a higher pressure than either of the
first and second operating pressure provided by the first and
second vacuum pumps 206, 212 respectively. However, the critical
pressure level may be required for the first and second vacuum
pumps 206, 212 to begin operation.
[0027] The shared vacuum pump 202 may be selectively coupled to the
first processing volume 208 while bypassing the first vacuum pump
206 by a first roughing valve 218 disposed between the first
processing volume 208 and the shared vacuum pump 202. For example,
and as discussed in the methods below, the first vacuum pump 206
may be isolated from the first processing volume 208 by the first
gate valve 210 while a pressure of the first processing volume 208
is lowered to below the critical pressure level, for example,
suitable for operation of the first vacuum pump 206. Additional
embodiments where the first vacuum pump 206 may be bypassed are
also discussed below.
[0028] Similarly, the shared vacuum pump 202 may be selectively
coupled to the second processing volume 214 while bypassing the
second vacuum pump 212 by a second roughing valve 220 disposed
between the second processing volume 214 and the shared vacuum pump
202. For example, and as discussed in the methods below, the second
vacuum pump 212 may be isolated from the second processing volume
214 by the second gate valve 216 while a pressure of the second
processing volume 214 is lowered to below the critical pressure
level, for example, suitable for operation of the second vacuum
pump 206. Additional method embodiments where the second vacuum
pump 212 may be bypassed are also discussed below.
[0029] The shared vacuum pump 202 may be selectively coupled to the
first vacuum pump 206 by a first isolation valve 222. For example,
the first isolation valve 222 may be disposed between the high
pressure 207 of the first vacuum pump 206 and the shared vacuum
pump 202. In some embodiments, for example when the first vacuum
pump 206 is in operation, the first isolation valve is open to
allow gases or the like removed from the first processing volume
208 by the first vacuum pump 206 to be exhausted from the high
pressure side 207 of the first vacuum pump 206 to the shared vacuum
pump 202.
[0030] Similarly, the shared vacuum pump 202 may be selectively
coupled to the second vacuum pump 212 by a second isolation valve
224. For example, the second isolation valve 224 may be disposed
between the high pressure 213 of the second vacuum pump 212 and the
shared vacuum pump 202. In some embodiments, for example when the
second vacuum pump 212 is in operation, the second isolation valve
is open to allow gases or the like removed from the second
processing volume 214 by the second vacuum pump 212 to be exhausted
from the high pressure side 213 of the second vacuum pump 212 to
the shared vacuum pump 202.
[0031] The shared gas panel 204 may be coupled to each of the
process chambers 110, 111 for providing one or more process gases
to the first and second processing volumes 208, 214. For example,
the shared gas panel may include one or more gases sources (not
shown), for example where a gas from each gas source is metered out
to each process chamber by one or more flow controllers, such as a
mass flow controller, flow ratio controller or the like. Each gas
source may be provided to each processing volume independently or
to both processing volumes simultaneously, for example, to perform
the same process in both process chambers 110, 111 simultaneously.
As used herein, simultaneously means that the processes being
performed in the two processing volumes at least partially overlap,
begin after both substrates are delivered to the two processing
volumes, and end prior to removal of either substrate from either
of the two processing volumes.
[0032] A first three-way valve 226 can be disposed between the
shared gas panel and the first processing volume 208 of the process
chamber 110 to provide a process gas from the shared gas panel 204
to the first processing volume 208. For example, the process gas
may enter the process chamber 110 at a first showerhead 228 or any
suitable gas inlet(s) used for providing a process gas to a process
chamber. Further, the first three-way valve 226 may divert the
process gas from the shared gas panel 204 (e.g., bypassing the
first processing volume 208) into a foreline conduit 230 coupled to
the shared vacuum pump 202. Further, as shown, the foreline conduit
230 may couple the shared vacuum pump 202 to the high pressure side
207 of the first vacuum pump 206 and directly couple the shared
vacuum pump 202 to the first processing volume 208.
[0033] The first showerhead 228 may include an electrode having a
first RF power source 229 coupled thereto, for example, for
striking a plasma in the first processing volume 208 from a process
gas. Alternatively, the first RF power source 229 may be coupled to
an electrode separate from the first showerhead 228 (not shown) or
coupled to one or more inductive coils (not shown) disposed outside
the first processing volume 208.
[0034] A second three-way valve 232 can be disposed between the
shared gas panel 204 and second processing volume 208 of the
process chamber 111 to provide a process gas from the shared gas
panel 204 to the second processing volume 208. For example, the
process gas may enter the process chamber 111 at a second
showerhead 234 or any suitable gas inlet(s) used for providing a
process gas to a process chamber. Further, the second three-way
valve 232 may divert the process gas from the shared gas panel 204
(e.g., bypassing the second processing volume 214) into the
foreline conduit 230 coupled to the shared vacuum pump 202.
Further, as shown, the foreline conduit 230 may couple the shared
vacuum pump 202 to the high pressure side 213 of the second vacuum
pump 212 and directly couple the shared vacuum pump 202 to the
second processing volume 214.
[0035] The second showerhead 234 may include an electrode having a
second RF power source 235 coupled thereto, for example, for
striking a plasma in the second processing volume 214 from a
process gas. Alternatively, the second RF power source 235 may be
coupled to an electrode separate from the second showerhead 234
(not shown) or coupled to one or more inductive coils (not shown)
disposed outside the second processing volume 214.
[0036] In some embodiments, for example where a substrate is
processed in only one of the process chambers of the twin chamber
processing system while the other process chamber remains idle, the
first and second three-way valves 226, 232 may be used to divert
the process gases away from the idle process chamber and to the
foreline conduit 230. Diverting the processes gases away from the
idle process chamber may prevent the process gases from condensing
on one or more interior surfaces or components (e.g., interior
walls, substrate support, gas lines, or the like), thereby reducing
or eliminating contamination, corrosion, particle formation, or the
like that may result from the condensation of the process
gases.
[0037] The first and second three-way valves 226, 232 may operate
in response to a process endpoint detected, for example, by a first
endpoint detector 236 for detecting the process endpoint in the
process chamber 110 and by a second endpoint detector 238 for
detecting the process endpoint in the process chamber 111. The
first and second endpoint detectors 236, 238 may be configured to
determine an endpoint by optical emission spectroscopy (OES),
interferometry, or other suitable means of endpoint detection. In
some embodiments, the first and second endpoint detectors 236, 238
may be part of a process controller and may be configured to
determine an endpoint by elapsed time based upon empirical or
modeled calculations. In some embodiments, the process endpoint
time may be part of a process recipe in the process controller and,
in some embodiments, may be adjusted via advanced process control
techniques (such as, incoming film or substrate variations,
feedback and/or feedforward information, or the like). For example,
a controller, for example such as the system controller 144 or a
individual controller (not shown) coupled to one or more of the
components of the twin chamber processing system 101, may be
configured to receive a first signal form the first endpoint
detector 236 when the process endpoint is reached in the process
chamber 110 and to terminate the process, for example, by
instructing the first three-way valve 226 to divert a process gas
into the foreline conduit 230 and/or by turning off the RF power to
the process chamber, if the process endpoint has not been reached
in a process running in the process chamber 111. For example,
although a process may be synchronized in each process chamber 110,
111 initially, the process may end at different times in each
process chamber 110, 111 due to, for example, small variations in a
substrate being processed, substrate temperature, plasma density or
flux, or the like in each process chamber 110, 111. In addition,
process endpoints in each chamber may vary, for example, due to any
one or more of: substrate variation between process chambers,
upstream processing prior to entering each process chamber 110,
111, feedforward control to correct substrate variations due to
upstream processing, feedback control to adjust process parameters
in response to downstream processing, or the like. Similarly, the
controller may be configured to receive a second signal from the
second endpoint detector 238 when the process endpoint is reached
in the process chamber 111 and to instruct the second three-way
valve 232 to divert a process gas into the foreline conduit 230 if
the process endpoint has not been reached in a process running in
the process chamber 110.
[0038] Alternatively or in combination, and as discussed in the
method 300 below, when an endpoint is reached in either process
chamber 110, 111 as determined by the respective first and second
detectors 236, 238, the controller 144 may shut off a plasma in
each process chamber 110, 111 by turning off the respective first
and second RF power sources 231, 235. When each RF power source is
turned off, the process gas may continue to flow to each process
chamber, or the process gas flow may be turned off along with each
RF power source, or the process gas may be diverted by each
three-way valve as discussed above.
[0039] Alternatively, a process need not be precisely synchronized
in both process chambers 110, 111 and for example may begin in each
chamber when a substrate has reached the appropriate process
temperature or another similar process condition. Accordingly, when
a process endpoint is reach in a given chamber, the process gas is
diverted by a three-way valve into the foreline conduit 230 until
the process endpoint is reached in the adjacent chamber prior to
removing the substrates from the chambers 110, 111 or prior to
beginning a further processing step.
[0040] The shared gas panel may further provide a gas for purging
the process chambers 110, 111. For example, a vent line 240 may be
selectively coupled to each of the first and second processing
volumes 208, 214 either directly (as shown) or via the high
pressure sides 207, 213 of respective first and second vacuum pumps
206, 212 (not shown). For example, the purge gas may include
nitrogen (N.sub.2), argon (Ar), helium (He), or the like. The purge
gas may be selectively provided to the first processing volume 208
via a first purge valve 242 disposed between the shared gas panel
204 and the first processing volume 208. Similarly, the purge gas
may be selectively provided to the second processing volume 214 via
a second purge valve 244 disposed between the shared gas panel 204
and the second processing volume 214. Further, in applications
where the purge gas is utilized to vent each process chamber 110,
111 to atmosphere, a vent (not shown), for example such as a valve
or the like, may be provided for each chamber 110, 111 such that
each chamber 110, 111 may be vented to atmosphere independently
from the other chamber.
[0041] Returning to FIG. 1, the system controller 144 is coupled to
the processing system 100. The system controller 144 controls the
operation of the system 100 using a direct control of the process
chambers 110, 111, 112, 132, 128, 120 of the system 100 or
alternatively, by controlling individual controllers (not shown)
associated with the process chambers 110, 111, 112, 132, 128, 120
and/or each twin chamber processing system 101, 103, 105 and the
system 100. In operation, the system controller 144 enables data
collection and feedback from the respective chambers and system
controller 144 to optimize performance of the system 100. In some
embodiments, the system controller 144 may individually control
each process chamber (e.g., process chambers 110, 111, 112, 132,
128, 120) within each twin chamber processing system (e.g., twin
chamber processing system 101, 103, 105) independent of one
another. For example, in some embodiments, neither, one, or both of
the process chambers within each twin chamber processing system may
be utilized to process a substrate regardless of the processing
state of the other process chamber within that particular twin
chamber processing system. In such embodiments, the system
controller 144 may be configured to support automated substrate
handling regardless of the state of either or both of the process
chambers of the twin chamber processing system.
[0042] The system controller 144 generally includes a central
processing unit (CPU) 138, a memory 140, and support circuit 142.
The CPU 138 may be one of any form of a general purpose computer
processor that can be used in an industrial setting. The support
circuits 142 are conventionally coupled to the CPU 138 and may
comprise cache, clock circuits, input/output subsystems, power
supplies, and the like. The software routines, such as a method 300
or 400 described below for controlling one or more chamber
processes, such as reducing pressure, venting or purging each
chamber of a twin chamber processing system, when executed by the
CPU 138, transform the CPU 138 into a specific purpose computer
(controller) 144. The software routines may also be stored and/or
executed by a second controller (not shown) that is located
remotely from the system 100.
[0043] A method 300 for processing substrates in the process
chambers of a twin chamber processing system is depicted in FIG. 3
and described below with respect to the twin chamber processing
system 101 depicted in FIG. 2. Further, the inventive methods
disclosed herein need not be limited to only two process chambers
sharing common resources, such as the twin chamber processing
system 101. For example, the inventors contemplate that processing
systems having three or more process chambers which shared common
resources (not shown) may benefit from the inventive methods
disclosed herein. The inventive method facilitates the operation of
individual process chambers having shared resources according to
their own individual requirements, while enabling synchronization
of shared resources, such as a shared gas panel, that provides
resources to multiple process chambers. For example, a shared
resource (such as process gases) may be provided to all process
chambers. As soon as any process chamber is ready for processing, a
plasma may be formed by providing RF to begin processing. When the
process is done, the process may be terminated (for example, by
turning off RF power) and the process chamber may wait until all
other process chambers coupled to the shared resource are finished
processing. Upon completion of processing by all process chambers,
the shared resource may be set at desired for a next step and the
cycle may continue. Thus, the individual process chambers can run
independently while the shared resource is in a given state, and
the process chambers may wait until all process chambers are ready
for the next transition of the shared resource to a new state
desired for subsequent processing.
[0044] The method 300 begins at 302 by flowing a process gas from
the shared gas panel 204 of the twin chamber processing system 101
to the first processing volume 208 of the process chamber 110
having the first substrate 203 disposed therein and to the second
processing volume 214 of the process chamber 111 having the second
substrate 215 disposed therein. For example, the first three-way
valve 226 and the second three-way valve 232 may be configured to
provide the process gas to the first and second showerheads 228,
234 respectively such that the process gas enters the first and
second processing volumes 208, 214.
[0045] At 304, a first plasma may be formed from the process gas in
the first processing volume 208 to process the first substrate 203
and a second plasma may be formed from the process gas in the
second processing volume 214 to process the second substrate 215.
For example, the first plasma may be formed by providing RF power
from the first RF power source 229 to first processing volume 208
to form the first plasma from the process gas. Similarly, the
second plasma may be formed by providing RF power from the second
RF power source 235 to the second processing volume 214 to from the
second plasma for the process gas.
[0046] A process performed in the process chambers 110, 111 may be
synchronized or unsynchronized. In a synchronized process,
processing does not occur in either chamber until both chambers
have reached a desired state to form the plasma and begin
processing. In an unsynchronized process, processing may begin in
either chamber as soon as the particular chamber has reached a
desired state to form the plasma and begin processing. For example,
in some embodiments, at least one of heating the first and second
substrates 203, 215 to a substantially similar temperature,
providing a substantially similar pressure in both the first and
second processing volumes 208, 214, or providing a substantially
similar flow rate of the process gas to both the first and second
processing volumes 208, 214 occurs prior to forming the first and
second plasmas. Accordingly, by attempting to substantially
equilibrate one or more processing conditions in both process
chambers 110, 111, the process chambers 110, 111 may be
synchronized prior to forming the first and second plasma in the
process chambers 110, 111. Synchronizing the process conditions in
the process chambers 110, 111 may be utilized such that a first
endpoint for processing the first substrate 203 may be reached at
about the same time as a second endpoint for processing the second
substrate 215. However, in some embodiments, even if the process
conditions are synchronized, the first and second endpoints may be
reached at different times.
[0047] Alternatively, the first plasma may be formed from the
process gas prior to the second plasma. For example, at least one
of the first processing volume 208 reaches at least one of an
operating pressure or operating flow rate of the process gas prior
to second processing volume 214, or the first substrate 203 reaches
an operating temperature prior to the second substrate 215.
Accordingly, due to the processing conditions being reached in the
process chamber 110 prior to the process chamber 111, the first
plasma may be formed prior to the second plasma. Accordingly, when
the process conditions are unsynchronized, the first endpoint for
processing the first endpoint for processing the first substrate
203 may be reached prior to the second endpoint for processing the
second substrate 215.
[0048] At 306, the first processing volume 208 may be monitored
with the first endpoint detection system 236 and the second
processing volume 214 may be monitored with a second endpoint
detection system 238 to determine if a process endpoint is reached
in either processing volume. For example, the process endpoint may
be determined by monitoring one or more of a critical concentration
of the process gas, a material from the first and second substrates
or a byproduct from a reaction between the first and second
substrates and the process gas and/or first and second plasmas. For
example, the process endpoint may be determined by optical
measurement or any suitable means for detecting any of the
aforementioned process endpoints.
[0049] At 308, the method 300 may proceed by either of two
alternatives, 308A or 308B, where the processes in the first and
second process chambers 110, 111 are terminated either
simultaneously or sequentially and either upon reaching the first
process endpoint or the second process endpoint. The decision of
whether or not to terminate the first-endpoint reached process may
be made based at least in part upon the selectivity of the process
being performed. For example, if an etch process is being performed
in each process chamber 110, 111 and the process is highly
selective (e.g., the etch process does not etch a mask and/or
materials underlying the desired material being etched, or etches
such materials at a comparatively low rate), then a decision may be
made to continue processing in the chamber until the second process
endpoint is reached. In such a scenario, continuing the first
process may not present much risk of defect or damage to the
substrate or structures being formed thereon due to the high
selectivity of the process. One the other hand, where the
selectivity is low (e.g., the etch process etches the mask and/or
materials underlying the desired material being etched at a rate
near the etch rate of the desired material being etched), then a
decision may be made to terminate processing in the chamber
immediately upon reaching the process endpoint. In such a scenario,
continuing the first process may present a high risk of defect or
damage to the substrate or structures being formed thereon due to
the low selectivity of the process.
[0050] At 308A, when a first endpoint is reached in the first
processing volume 208 for processing the first substrate 203, the
first and second plasma may be simultaneously terminated. For
example, the flow of the process gas may be stopped at the shared
gas panel 204, or the flow of the process gas may be diverted to
the foreline conduit 230 by both the first and second three-way
valves 226, 232, the first and second RF power sources 229, 235 may
be turned off, or any combinations thereof.
[0051] In some embodiments, the first endpoint may be reached prior
to a second endpoint in the second processing volume 214 for
processing the second substrate 215. Accordingly, the first and
second plasmas can be terminated based upon the first endpoint
being an earlier endpoint than the second endpoint. Alternatively,
in some embodiments, the first endpoint may be reached after the
second endpoint in the second processing volume 214. Accordingly,
the first and second plasmas can be terminated based upon the first
endpoint being a later endpoint than the second endpoint. In some
embodiments, the first endpoint may be reached about simultaneously
with the second endpoint in the second processing volume 214 for
processing the second substrate. Thus, according to 308A, both
plasmas are terminated about simultaneously, and may be terminated
upon the first endpoint being detected (or both endpoints being
about simultaneously detected) or upon the last endpoint being
detected.
[0052] Alternatively, at 308B, when the first endpoint is reached
in the first processing volume 208 for processing the first
substrate 203, the first plasma may be terminated while continuing
to provide the second plasma in the second processing volume 214
until the second endpoint is reached for processing the second
substrate 215. For example, the first plasma may be terminated in
any suitable manner, such as turning off the RF power source 231.
In some embodiments, RF power provided to the first processing
volume 208 by the first RF power source 229 may be turned off while
continuing to flow the process gas to the first processing volume
208 after the RF power provided by the first RF power source 229 is
terminated. In some embodiments, the flow of the process gas to the
first processing volume 208 may continue until the second endpoint
is reached.
[0053] In some embodiments, RF power provided to the first
processing volume 208 by the first RF power source 229 may be
turned off and the process gas may be diverted prior to entering
the first processing volume 208 when the RF power provided by the
first RF power source 229 is terminated. For example, the three-way
valve 226 may be used to divert the process gas into the foreline
conduit 230. In some embodiments, the process gas may be diverted
into the foreline conduit 230 by the three-way valve 226 until the
second endpoint is reached for processing the second substrate
215.
[0054] After the second endpoint is reached for processing the
second substrate 215 in the second processing volume 214, the
second plasma may be terminated. For example, the second plasma may
be terminated by any of the methods discussed above for terminating
the first plasma, such as diverting the process gas into the
foreline conduit 230 using the three-way valve 232 or the like. The
method similarly proceeds if the second endpoint is reached prior
to the first endpoint being detected. Thus, at 308B, the first and
second plasmas are treated independently and extinguished solely
upon the process endpoint being detected for the particular process
chamber. For example, if an etch process is being performed in each
process chamber 110, 111 simultaneously, where the etch process is
highly selective, for example where a first material of the
substrate is etched a substantially faster rate than a second
material of the substrate, then the first and second plasmas can be
terminated when the first and second endpoints are individually
reached in each process chamber 110, 111.
[0055] Optionally, at 310, 302-308A or 302-308B may be repeated
with a second process gas to further process the first and second
substrates 203, 215. For example, if 302-308A were used to process
the first and second substrates 203, 215 with the process gas,
either of 302-308A or 302-308B may be used to further process the
first and second substrates 203, 215. Similarly, if the steps
302-308B were used to process the first and second substrates 203,
215 with the process gas, either steps 302-308A or 302-308B may be
used to further process the first and second substrates 203, 215.
The repeated processing may occur, for example, for multiple
sub-steps of a multiple step recipe, or for multiple etch processes
that may be performed on a substrate in a single chamber. In
addition, upon completion of the processing of both substrates in
both process chambers, the substrates may be removed by the
substrate transfer robot and delivered to another process chamber
or to the load lock chambers for removal from the processing
system. Subsequently, new first and second substrates may be placed
in the respective process chambers by the substrate transfer robot,
either from different process chambers in the processing system or
from the factory interface via the load lock chambers, to begin
processing. The method 300 described above may then be repeated for
the new first and second substrates.
[0056] Further, and as discussed above, in each process where the
shared resource is in the same state, for example when the shared
resource is providing the first process gas to each process chamber
110, 111 as discussed above, each process chamber may operate
independently, for example where the first and second plasmas are
selectively terminated when the first and second endpoints are
independently reached in each chamber. Alternatively, other
examples of independent operation of each process chamber 110, 111
when the shared resource is in the same state, may include running
different processes, such as plasma or non-plasma processes, or
adjusting process conditions in each chamber such as substrate
temperature, flow rate, RF power intensity or the like based upon
feedforward or feedback control based on substrate variations,
chamber variations or the like. After each chamber 110,111 has
completed a process in synchronization or having independently
terminating endpoints, the process chambers 110, 111 may be
synchronized again, for example, when switching the shared resource
to a new state, for example when the shared resource is providing
the second process gas to each process chamber 110, 111 as
discussed above.
[0057] Although some of the above methods have been described with
respect to simultaneously performing a synchronized or
unsynchronized process on a first and second substrate 203, 215 in
a respective first and second process chamber 110, 111 of a twin
processing system 101, it is to be understood that the above
processes may be performed on a single substrate disposed in only
one of the first process chamber 110 or the second process chamber
111. For example, FIG. 4 depicts such a method 400.
[0058] In some embodiments, the method 400 may begin at 402 by
providing a substrate (e.g., substrate 203) to the first process
chamber 110 (or the second process chamber 111) of the twin
processing system 101. The substrate 203 may be provided to the
process chamber (i.e., process chamber 111 or 110) via, for
example, a transfer robot, such as the vacuum robot 130 described
above. The method described herein arbitrarily is illustrated with
respect to providing the substrate to the first process chamber.
However, the substrate could also be provided to the second process
chamber instead.
[0059] Next, at 404, one or more processing resources from a shared
processing resource may be provided to the substrate containing
process chamber. The shared processing resource may be any resource
suitable for substrate processing, for example, such as the shared
gas panel 204 or the shared vacuum pump 202 described above. In
some embodiments, for example, where the shared processing resource
is a shared gas panel 204, the shared gas panel 204 may provide a
process gas to the substrate containing process chamber to be
formed into a plasma, such described above. In such embodiments,
the shared gas panel 204 may provide the process gas at a flow rate
suitable for both the first and second process chamber 110, 111. In
some embodiments, one or more valves (e.g., the first and second
three-way valves 226, 232) may be used to divert the process gases
away from the non-substrate containing process chamber, for
example, to a foreline conduit (e.g., foreline conduit 230) of the
substrate containing process chamber. Diverting the processes gases
away from the non-substrate containing process chamber may prevent
the process gases from condensing on one or more interior surfaces
or components (e.g., interior walls, substrate support, gas lines,
or the like), thereby reducing or eliminating contamination,
corrosion, particle formation, or the like that may result from the
condensation of the process gases.
[0060] Next, at 406, a process is performed on the substrate in the
substrate containing process chamber. The process may be any
process that may be performed on a substrate, for example, such as
an etch, deposition, anneal, or the like. In some embodiments, the
process may be similar to the plasma process described above with
respect to FIG. 3.
[0061] In some embodiments, while the process is being performed on
the substrate at 406, the non substrate containing process chamber
may sit idle. Alternatively, in some embodiments, at 408, a service
operation may be optionally performed on the non substrate
containing process chamber. The service operation may be any type
of operation, for example such as maintenance, cleaning, testing,
monitoring, or the like. Non-limiting examples of such service
operations and methods of performing such services may be found in
U.S. Provisional Patent Application Ser. No. 61/330,177, filed Apr.
30, 2010, by James P. Cruse et al., and entitled, "Methods for
Monitoring Processing Equipment." In some embodiments, the non
substrate containing process chamber may be decoupled from the
shared resources and/or disabled to allow for service operations to
be performed without affecting the process being performed in the
other process chamber.
[0062] In some embodiments, while the process is being performed on
the substrate at 406, a process requiring one or more of the shared
resources may be started in the non substrate containing process
chamber. The process may be any process, for example, such as the
service operations or substrate processes described above. However,
providing the one or more of the shared resources to the non
substrate containing process chamber while the process is being
performed on the substrate may cause the one or more of the shared
resources to be delayed or otherwise provided in an inconsistent
manner, thereby causing non-uniformities in the process being
performed on the substrate. Accordingly, in some embodiments, at
410, in some embodiments, the process being performed on the
substrate 203 may optionally be paused to allow the non substrate
containing process chamber the use of the one or more shared
resources. After the one or more shared resources is provided to
the non substrate containing process chamber, the process in the
substrate containing process chamber may resume.
[0063] After the process is performed at 406, the method generally
ends. The substrate may proceed for further processing or may be
removed from the process chamber. Alternatively, in some
embodiments, a subsequent substrate may be provided to the process
chamber and the method may repeat.
[0064] Thus, methods for processing substrates in a twin chamber
processing system are disclosed herein. The inventive methods
advantageously control operation of chamber processes, such process
gas flow, plasma generation, and the like, when shared resources
are used between each chamber of the twin chamber processing
system, such that processes can be run simultaneously on substrates
in each process chamber of the twin chamber processing system and
process quality can be maintained.
[0065] While the foregoing is directed to embodiments of the
present invention, other and further embodiments of the invention
may be devised without departing from the basic scope thereof.
* * * * *